Are you getting the dreaded “paper jam” error? Usually this first shows up when trying to print borderless prints, as the PW (Paper Width) light sensor is trying to find the exact edge of the paper, but there is a problem with the signal. I found the issue on my printer was with corrosion on the electrical connector for the PW sensor. I also found corrosion on the ink mark sensor connector. I was able to fix this with no new parts, just a few supplies from my local automotive store. Here are a few notes and pictures.

The PW and Ink mark sensors are on the underside of the printer head assembly. The Epson manual indicates that you have to remove the printer head assembly to access these sensors. This however is a very involved procedure, requiring tools valued well in excess of a new printer. I found that these sensors can be accessed from below the printer frame, once the plastic housing is removed, without removal of the printer head. All in all, the following procedures can be carried out in less than 2 hours.

In my opinion Epson is as fault here. Obviously corrosive vapors are encountered from printing, they should have used a little dielectric grease on these connections!

Remove the covers from the printer

Remove the frame sub-assembly from the lower housing and flip onto it’s back. Be careful not to twist the frame as it is not that rigid without the plastic housing.

Slide the printer head/carriage to the far left. You can see the PW and ink mark sensors now from the bottom left of the printer (since the printer is on it’s back, the left side facing you).

Unscrew the single black screw, carefully remove the sensors from the cables (use needle nose pliers to hold each cable (on the blue re-enforced section).

Clean the sensors. I used 190proof alcohol (drying afterwards of course), and mechanically scraped between solder connections. I also used 2000 grit sandpaper (from automotive store, sold for fine paint work), to clean the inside of the ribbon connectors, fold and insert repeatedly. This is where I found corrosion, on the connectors... I placed dielectric grease (also sold at automotive stores to protect electrical connections from corrosion) in the ribbon connectors to protect them from further corrosion. I also used the 2000 grit sandpaper to clean the electrical connections on the cables themselves, carefully cleaning afterwards with paper towel soaked in WD-40.

Re-assemble, and make sure you run all the alignment programs with the Epson service utility.